DFG/TFG 316-435
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Operating instructions 51287765 11.15 11.15DFG 316 DFG 320 DFG 425 DFG 430 DFG 435 TFG 316 TFG 320 TFG 425 TFG 430 TFG 435 1JUNGHEINRICH Machines. Ideas. Solutions.
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I\J 11.15 EN
Declaration of Conformity
Jungheinrich AG, Friedrich-Ebert-Damm 129, 22047 Hamburg, Germany
Manufacturer or agent acting in the European Union
Model Option Serial no. Year of manufacture
DFG 316
DFG 320
DFG 425
DFG 430
DFG 435
TFG 316
TFG 320
TFG 425
TFG 430
TFG 435
Additional information
On behalf of Date
@ EC Declaration of Conformity
The undersigned hereby declare that the powered industrial truck described below in detail complies with the European Directives 2006/42/EC (Machinery Directive) and 2004/108/EEC (Electromagnetic Compatibility - EMC) including amendments as well as the legislative decree to incorporate the directives in national law. The signatories are in each case individually authorised to compile the technical documents.
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Foreword
Notes on the operating instructions
The present ORIGINAL OPERATING INSTRUCTIONS are designed to provide sufficient instruction for the safe operation of the industrial truck. The information is provided clearly and concisely . The chapters are arranged by letter and the pages are numbered continuously.
The operator manual details different industrial truck models . When operating and servicing the industrial truck, make sure that the particular section applies to your truck model.
Our trucks are subject to ongoing development. We reserve the right to alter the design, equipment and technical features of the system. No guarantee of particular features of the truck should therefore be assumed from the present operating instructions
Safety notices and text mark-ups
Safety instructions and important explanations are indicated by the following graphics :
,&
DANGER!
Indicates an extremely hazardous situation Failure to comply with this instruction will result in severe irreparable injury and even death.
WARNING!
Indicates an extremely hazardous situation. Failure to comply with this instruction may result in severe irreparable injury and even death.
,& CAUTION!
Indicates a hazardous situation. Failure to comply with this instruction may result in slight to medium injury .
NOTE
Indicates a material hazard. Failure to comply with this instruction may result in material damage.
Used before notices and explanations.
Indicates standard equipment
Indicates optional equipment
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Friedrich-Ebert-Damm 129 22047 Hamburg - Germany
Tel: +49 (0) 40/6948-0
www.jungheinrich.com
6 Copyright
of these operating instructions
with JUNGHEINRICH AG.
Copyright
remains
Jungheinrich Aktiengesellschaft
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Contents A Correct Use and Application .. .. .. .. .. .. .. .. .. .. .. . .. .. .. .. .. ... .. .. ... .. .. .. .. 11 1 General.................................................................................................... 11 2 Correct application................................................................................... 11 3 Approved application conditions.............................................................. 12 4 Proprietor responsibilities 13 5 Adding attachments and/or optional equipment...................................... 13 B Truck Description.................................................................... 15 1 Application 15 1.1 Truck models and rated capacity............................................................. 15 2 Assemblies and Functional Description................................................... 16 2.1 Travel direction definition......................................................................... 16 2.2 Assembly Overview................................................................................. 17 2.3 Functional Description 18 3 Technical Specifications.......................................................................... 20 3.1 Performance data .. .. .. .. ... ....... .. .. ........... .. .. ....... ... .. .. ....... .. .. .. .. ........ ... .. .. ... 20 3.2 Dimensions.............................................................................................. 23 3.3 Weights.................................................................................................... 26 3.4 Mast versions ........ .. . ....... .... .. . ........ ... .. .. ....... .... .. . ....... .. .. .. . ........ .. .. .. .. ...... 27 3.5 Tyre type.................................................................................................. 32 3.6 Engine Data............................................................................................. 33 3.7 EN norms................................................................................................. 34 3.8 Conditions of use..................................................................................... 35 3.9 Electrical Requirements........................................................................... 35 4 Identification Points and Data Plates....................................................... 36 4.1 Data plate 38 4.2 Truck capacity plate................................................................................. 39 4.3 Attachment capacity plate 41 5 Stability.................................................................................................... 41 6 Wind loads............................................................................................... 41 C Transport and Commissioning .. .. .. .. .. . .. .. .. .. .. .. .. .. .. .. .. ... .. .. .. . .. .. . 43 1 Transport .. ......... .. .. ............. .. . ............ .. .. ......... .. .. ........ .... .. . ........ .. .. .. . ....... 43 2 Truck laden.............................................................................................. 43 2.1 Centre of gravity of the truck................................................................... 43 2.2 Lifting the truck by crane ......................................................................... 44 2.3 Loading with another industrial truck....................................................... 46 3 Securing the truck during transport......................................................... 47 4 Using the Truck for the First Time .. ...... .. ... .. .. .. ..... .. .. .. .. .............. ............. 49 D Fuelling the Truck.................................................................... 51 1 General.................................................................................................... 51 1.1 Safety regulations for handling diesel fuel and LPG................................ 51 1.2 LPG system relief valve........................................................................... 53 z 2 UJ Adding diesel........................................................................................... 54 "' 2.1 "": Fuelling.................................................................................................... 54 7
o o o 2.2 Fuelling with fuel containers 56 2.3 Fuel display (DFG only) 57 3 LPG containers ....................................................................................... . 58 3.1 LPG bottles 58 3.2 LPG tank ( ) 60 E Operation ............................................................................... . 63 1 Safety Regulations for the Operation of the Forklift Truck 63 2 Displays and Controls 65 2.1 Control panel with display unit ................................................................ . 67 3 Description of the Display and Controls on the Armrest ( ) 71 3.1 Pilots 73 3.2 Control panel with display unit 75 4 Preparing the Truck for Operation 79 4.1 Checks and Operations to Be Performed Before Starting Daily Work ... . 79 4.2 Entry and exit. 80 4.3 Setting up the operator position 81 4.4 Seat Belt ................................................................................................. . 92 5 Industrial Truck Operation 93 5.1 Safety regulations for truck operation 93 5.2 Preparing the truck for operation 96 5.3 Parking the truck securely 99 5.4 Battery Isolator ........................................................................................ 100 5.5 Travel 101 5.6 Steering 103 5.7 Brakes .................................................................................................... . 104 5.8 Adjusting the forks 106 5.9 Replacing the forks 107 5.10 Lifting, transporting and depositing loads .............................................. .. 108 5.11 Operating the Lift Mechanism and Integrated Attachments 110 5.12 Safety instructions for operating additional attachments ........................ . 127 5.13 Operating additional attachments for the SOLO-PILOT 130 5.14 Operating Additional Attachments for SOLO-PILOT on the Armrest.. 133 5.15 Operating Additional Attachments for MULTI-PILOT on the Armrest.. .. .. 136 5.16 Operating Additional Attachments for DUO-PILOT on the Armrest.. 139 5.17 Fitting additional attachments 142 6 Towing trailers ........................................................................................ . 144 7 Optional equipment 146 7.1 Heating .................................................................................................... 146 7.2 Removable load backrest 146 7.3 Adding window washer system fluid 147 7.4 Particle Filter (DFG) ................................................................................. 148 7.5 CanCode Keypad ( ) 153 7.6 USB charger module in armrest 168 7.7 Control Layout "N" on the Armrest. ......................................................... . 169 8 Troubleshooting 171 8.1 Troubleshooting 171 8.2 Operating the truck without its own drive system .................................. .. 174 F Industrial Truck Maintenance 181 1 Operational Safety and Environmental Protection 181 z w 2 Maintenance Safety Regulations ............................................................ . 182 I.O 8
o z UJ "' .... .... .... 2.1 Working on the electrical system............................................................. 183 2.2 Consumables and used parts.................................................................. 183 2.3 Wheels..................................................................................................... 183 2.4 Lift Chains................................................................................................ 184 2.5 Hydraulic system 184 2.6 Working in the vicinity of the engine........................................................ 185 3 Lubricants and Lubrication Schedule 187 3.1 Handling consumables safely.................................................................. 187 3.2 Lubrication Schedule............................................................................... 189 3.3 Consumables........................................................................................... 190 4 Maintenance and repairs......................................................................... 193 4.1 Preparing the truck for maintenance and repairs ............ ...... .. .. .... ...... .. .. 193 4.2 Lifting and jacking up the truck safely...................................................... 194 4.3 Opening the Engine Cover...................................................................... 195 4.4 Opening the Engine Cover with Comfort Seat ( ) 196 4.5 Removing the Covers.............................................................................. 200 4.6 Removing the Floor Plate........................................................................ 201 4. 7 Checking the Wheel Mounting................................................................. 202 4.8 Replacing wheels .. ...... ... ........... ............... ....... ....... ......... ...... ........ ..... ..... 203 4.9 Hydraulic system ................. ...... ............... ............. ........ ....... ......... ..... ..... 205 4.1 O Engine maintenance................................................................................ 208 4.11 Checking electrical fuses......................................................................... 221 4.12 Cleaning.................................................................................................. 225 4.13 Starter battery.......................................................................................... 227 4.14 Exhaust system .... .. .. ...... ....... .. .. ............ .. .. ......... .. ......... .... .. ......... .... .. ..... 228 4.15 Transmission and Drive Axle................................................................... 229 4.16 Brake ....... .. .. ... ........ .. .... ........ .. .... .......... .. .. ........ .. .. .. ........ .. .. .. ........ .. .. .. ..... 230 4.17 Restoring the truck to service after maintenance and repairs ................. 231 5 Decommissioning the Industrial Truck..................................................... 232 5.1 Prior to decommissioning ....... ........ ...... ...................... ..... ... ........... ... ....... 233 5.2 During decommissioning .. .. .............. ................ ............ .............. ............. 233 5.3 Restoring the truck to service after decommissioning 234 6 Safety tests to be performed at intervals and after unusual incidents .. .. . 235 7 Final de-commissioning, disposal............................................................ 236 8 Human vibration measurement............................................................... 236 G Maintenance and Inspection ................................................... 237 1 Maintenance checklist DFG 316-435 238 1.1 Owner ... .. .. ........... .. ............ .. .. ........... .. ............ .. ............ .. ............ .. .... ....... 238 1.2 Customer Service 240 2 Maintenance checklist TFG 316-435....................................................... 247 2.1 Owner...................................................................................................... 247 2.2 Customer Service 249 9
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NOTE
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• Thank you very much for reading the preview of the manual.
• You can download the complete manual from: www.heydownloads.com by clicking the link below
• Please note: If there is no response to CLICKING the link, please download this PDF first and then click on it.
CLICK HERE TO DOWNLOAD THE COMPLETE MANUAL
CLICK HERE TO DOWNLOAD THE COMPLETE MANUAL
